System and method for attaching components within an inflatable object

ABSTRACT

A method and system for permanently attaching a component to the interior surface of an inflatable object where the component is provided with a coating of a heat activatable material that is heat sealed to a surface of a film that forms the inflatable object. The heat activatable material can be a heat activated adhesive to adhere the component to a plastic interior surface of the inflatable object or can be polyethylene material that is adhered to a polyethylene interior surface of the inflatable object. A combination of heat and pressure is used to affix the contacting surfaces together in a strong, welded bond. The component can be a sound module, light module or decorative component that is sealed within the interior of the finally constructed inflatable object.

FIELD OF THE INVENTION

The invention generally relates to inflatable objects such as balloons,and more particularly, to a system to attach a component within theinterior surface of an inflatable object.

BACKGROUND

There are, of course, many different types of inflatable objects such asballoons that are used for a wide variety of purposes, that is, foradvertising, entertainment and simply for decorative adornment for ahouse or a festive occasion such as a birthday party or the like. Insuch cases, the balloon may be a typical metalized, bi axially orientednylon film and where there is an internal layer of a sealant materialsuch as polyethylene to seal the interior of the balloon and thusprevent the leakage of the gas, such as helium, to the exterior of theballoon envelope.

With such balloons, the balloons themselves are produced with automatedequipment such that the balloon material comprising the nylon film andan interior polyethylene surface, is heat sealed together in forming theperipheral edge of the balloon. As a further feature of some balloons,there may be a component contained within the balloon envelope, and suchcomponent may be a sound module, light module or other merely decorativeobject, that is, a sound module capable of producing a desired sound orsounds upon activation thereof, a light module to produce a light andthe like. As such, it is therefore necessary to incorporate certainadditional steps into the manufacturing techniques normally used toproduce the balloon in order to facilitate the addition of the componentand to produce a finished balloon having the component firmly affixedwithin the interior of the balloon itself.

Thus it would be advantageous to have a system that is capable ofintegration into the normal manufacturing procedures and steps in theproduction of a balloon without impeding the normal processing speed andtechniques and which can, readily and fairly simply, position acomponent within the interior of a balloon and affix the componentwithin that balloon such that the object is firmly affixed therein.

It would be further advantageous to provide a system for affixing acomponent such as a sound or light module firmly within the interior ofa balloon where the system utilizes a series of steps that can becarried out with the use of automated equipment and which firmly bondsthe component to the interior polyethylene surface of the balloonenvelope.

SUMMARY OF THE INVENTION

The present invention comprises a system to firmly affix a component,such as a sound module, within the interior of a balloon and a balloonhaving the component so affixed. The following description will, forconvenience, refer to the particular component as a sound module,however, it will be understood that there are a wide variety of othercomponents that can be used in carrying out the present invention,including, but not limited to, light modules or decorative components.

In carrying out the invention a nylon film is continually moved along atrack as is conventional in the present construction of a balloon. Atpredetermined intervals, the movement of the film is stopped in order tocarry out the steps of the present invention.

Thus, the present invention can be readily integrated into the normalsteps and procedures used in the present automated production ofballoons and the additional steps that are added to the normalproduction steps do not slow or impede the present systems and methodsto produce balloons.

As such, this invention permanently affixes a component, such as a soundmodule, to the internal surface of the nylon film that is normally usedin the production of decorative balloons. Such nylon film is generallycomprised of a metalized external skin (e.g., Mylar plastic) surfacewith an internal surface that is a polyethylene coating, although otherinternal surfaces can be utilized.

In any event, the nylon film travels with the polyethylene coated sidefacing upwardly. A component, such as a sound module that is generallycomprised of alight foam material is moved into position atop of thenylon film in a position so as to be affixed thereto. In order to makethe affixation of the sound module to the upper facing polyethylenesurface of the nylon film, the surface of the module is coated with amaterial that is activated by heat, such as a heat activatable adhesiveor a coating of a plastic such as polyethylene itself. In either event,the function of the heat activation is to make the material coating on asurface of the module take on an adhesive property so that it can beadhered to another surface.

In the case of a heat activatable adhesive, the heat converts thesurface into an adherent surface and, in the case of a plastic material,such as polyethylene, the heat softens and melts the polyethylenematerial so that it can adhere to another softened polyethylene surface.The heat activatable material generally at least partially covers thesurface of the module, such as along the peripheral area of the soundmodule. Thus, the bond, to be later described, is carried out by a heatand pressure bonding of the polyethylene side of the nylon film to theheat activatable material applied to the module.

In the aforedescribed steps of the invention, the sound module ispreferably picked up from a conveyer belt or other source of multiplesound modules by the pick up head of a robotic arm and that pick up headmay readily carry out the picking up of the module by applying a vacuumto the module to attach the sound module to the pick up head during thepositioning of the sound module. As such, the pick up head of therobotic arm can position the sound module at the predetermined locationupon the nylon film and the vacuum can be eventually dissipated so thatthe module will remain in affixed to the nylon film after the steps ofthe present invention have been accomplished.

Once the sound module has been deposited in the desired location atop ofthe nylon film, there is, in effect, a mating of the two surfaces, i.e.the upper, polyethylene surface of the nylon film and the lower surfaceof the sound module coated with a heat activatable material such that aheat and pressure sealing can be utilized to bond the two surfacestogether to result in a good, permanent affixation of the sound moduleto the surface of the nylon film.

That heat and pressure sealing can be carried out with the use of aheater having a hot head that is movable between a location where thehot head is remote from the surfaces to be bonded together to a positionwhere the hot head is located proximate to those surfaces, preferablyunderneath those surfaces and generally opposite to the location of thepick up head of the robotic arm. The hot head of the heater preferablyhas a external coating of polytetrafluoroethylene (Teflon) to preventsticking and the hot head can be moved by means of a piston up againstthe nylon film where the sound module and the nylon film is sandwichedbetween the head of the robotic arm and the hot head of the heater.

Accordingly, there can be heat and pressure applied to the surfaces tobe bonded, that is, the polyethylene surface of the nylon film and theheat activatable material coating on the module to bond those surfacestogether at least around the peripheral area of the sound module tosecurely affix the sound module to the nylon film. In one embodiment,there may also be a sheet of protective material, such aspolytetrafluoroethylene (Teflon) interposed between the hot head of theheater and the undersurface of the nylon film to prevent the hot head ofthe heater from actually contacting the nylon film during theapplication of heat and pressure to bond the sound module to the nylonfilm.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the invention may be obtained fromconsideration of the following description in conjunction with thedrawings in which:

FIG. 1 is a perspective view of a conveyer belt carrying sound modulesto be used in the present invention,

FIG. 2 is a perspective view of the apparatus of the present inventionwith a sound module in position to be applied to a nylon film of aninflatable object;

FIG. 3 a perspective view of the apparatus of the present invention witha sound module in contact with the nylon film of an inflatable object;

FIG. 4 is a side view of the apparatus of the present invention with aheater located proximate to the nylon film to apply heat thereto; and

FIG. 5 is a perspective view of the apparatus of the present inventionwith the sound module affixed to the nylon film of an inflatable object.

DETAILED DESCRIPTION

In FIG. 1, there is shown a perspective view of a of a conveyer 10 thatcontains a plurality of components, such as sound modules 12 that arecontinuously supplied by the conveyer 10 to provide those sound modules12 for use in carrying out the present invention. As can be seen, theconveyer 10 comprises a frame 14 with a plurality of movable members 16that carry the sound modules 12 to the desired position. Obviously, theuse of a conveyer 10 is but one means of providing a continuous supplyof sound modules 12 for use herein, however, there may be many othersystems that can make the individual sound modules 12 available on acontinuous basis, it only being of importance that whatever means isemployed, a continuous supply of sound modules 12 are available so as tonot interrupt the automated procedures and steps in the construction ofthe final balloon product.

There can also be seen in FIG. 1, a robotic arm 18 that is used with thepresent 10 invention to pick up one at a time, the sound modules 12 fromthe conveyer 10 to move the sound module 12 to position it at a locationto be secured to the interior of a balloon as will be later explained.

The robotic arm 18 generally comprises a pick up head 20 that is used topick up an individual sound module 12 from the conveyer 10 and the pickup head 20 can be supplied by a source of vacuum so that the vacuum canbe applied to the pick up head 20 to retain the sound module 12 to thepick up head 20 and, of course, the vacuum released to disengage thesound module from the pick up head 20, when desired. The robotic arm 18also includes a horizontal member 22 that allows the movement of thepick up head 20 generally parallel to the floor and a vertical member 24that allows the pick up head 18 to move vertically, all in accordancewith the automated procedure programmed into the overall system.

Turning next to FIG. 2, there is shown a perspective view of a typicalapparatus used to carry out the present invention. Accordingly, the pickup head 20 is positioned above the nylon film 26 and which has its uppersurface comprised of a plastic material such as a polyethylene layer 28.The opposite surface of the nylon film 26, that is, the exteriorsurface, is a skin 30 of a metalized surface, such as is produced byvacuum metallization and which becomes the exterior surface of the endproduct balloon when the 10 completed balloon is produced. The nylonfilm 26 can be co extruded with or coated with the polyethylene layer 28and that polyethylene layer 28 ultimately becomes the interior of theend product balloon, peripherally sealed, so as to retain the gas, suchas helium, that is introduced into the completed balloon when it is usedby the consumer.

As also can be seen, there is a heater 32 that has a hot head 34 at theupper portion thereof and the heater 32 is vertically movable by meanssuch as piston 36. As shown, the hot head 34 can be located in theposition of FIG. 2, that is, the hot head 34 is displaced away fromcontact or heat transmitting relationship with the nylon film 26.

One surface of the sound module 12, shown as the lower surface 38, hasapplied thereto a thin (in the order of microns) layer of a materialthat can be activated or made adhesive by the application of heat, suchas a heat activatable adhesive or polyethylene itself that softens andmelts upon the application of the heat and bonds to another polyethylenesurface. That activatable layer can be bonded to the surface 38 usingany number of conventional processes (heat or cold lamination), it onlybeing of importance that at least a portion of the lower surface 38 hasa heat activatable layer so that, as will be seen, the affixation of thesound module 12 to the polyethylene layer 28 of the nylon film 26results in a joining of the surfaces to produce a bonding of thosesurfaces that is strong and permanent. That portion of the lower surface38 of the sound module, can, of course be only the peripheral area ofthe sound module. As also can be noted, there is a 10 sheet of aprotective material 40, such as polytetrafluoroethylene (Teflon), thatis interposed between the hot head 34 and the nylon film 26 to allow inthe transfer of heat from the hot head 34 to the nylon film 26 whilepreventing sticking.

Turning briefly to FIG. 3, there can be seen a perspective view of theapparatus used to carry out the present invention and where the pick uphead 20 has been lowered so that the sound module 12 is laying atop ofthe polyethylene layer 28 of the nylon film 26.

In FIG. 4, there can be seen a side view showing the sound module 12sandwiched between the pick up head 20 and the polyethylene layer 28 ofthe nylon film 26. As also can be seen, the hot head 34 had been raisedvertically so that pressure can be applied as 10 well as heat to thenylon film 26 and the sound module 12 and the pressure is maintained ata predetermined temperature for a predetermined time to complete theweld to permanently bond the sound module 12 to the nylon film 26 and aseal has been effected between the respective surfaces of the nylon film26 and the sound module 12.

Turning finally to FIG. 5, there is shown a perspective view of theapparatus for carrying out the present invention and where the pick uphead 20 has been raised vertically and the vacuum has been vented sothat the pick up head 20 has freed itself from the sound module 12. Thehot head 34 has been returned to its lowered position and 10 the nylonfilm 26 now with the sound module 12 permanently welded thereto canadvance to the further conventional steps in the manufacture of aballoon, that is, another nylon film, the same as the nylon film 26 isoverlaid over the nylon film 26 and a heat seal, in the outline of theballoon is created with the sound module 12 captured in the completedballoon envelope. The upper nylon film is, of course, the same materialas the nylon film 26 with a polyethylene layer forming the interior ofthe balloon and the metalized surface forming the outer surface of thecompleted balloon.

It is to be understood that the invention is not limited to theillustrated and described form of the invention contained herein. Itwill be apparent to those skilled in the art that various changes may bemade without departing from the scope of the invention and the inventionis not considered limited to what is shown in the drawings and describedin the specification.

1. A method of affixing a component to a film for use in producing aninflatable object having an enclosed interior, said method comprisingthe steps of: providing a component having a surface having at least aportion thereof coated with a heat activatable material to be affixedinto the interior of the inflatable object, providing a film having onesurface thereof comprised of a plastic material that is adapted to beprocessed to form an inflatable object, placing the component upon theone surface of the film with the surface having at least a portionthereof coated with the heat activatable material contacting the onesurface of the film, and heat and pressure sealing the heat activatablematerial coated surface of the component to the one surface of the film.2. The method of affixing a component as defined in claim 1 wherein thestep of providing a film comprises providing a film having one surfacecomprised of polyethylene.
 3. The method of affixing a component asdefined in claim 1 wherein the step of providing a component comprisesproviding a component having a heat activatable surface of a heatactivatable adhesive.
 4. The method of affixing a component as definedin claim 2 wherein the step of providing a component comprises providinga component having a heat activatable surface of polyethylene.
 5. Themethod of affixing a component as defined in claim 1 wherein the step ofheat and pressure sealing the heat activatable material surface of thecomponent to the plastic surface of the film comprises providing aheater that is movable between a position displaced away from thesurfaces to a position in close proximity to the surfaces to cause heatemitted from the heater to reach the surfaces.
 6. The method of affixinga component as defined in claim 5 wherein the step of providing a heatercomprises providing a heater having a hot head coated with a non sticksurface.
 7. The method of affixing a component as defined in claim 5wherein the step of heat and pressure sealing the heat activatablematerial coated surface of the component to the polyethylene surface ofthe nylon film comprises positioning a protective material intermediatethe heater and the polyethylene surfaces.
 8. The method of affixing acomponent as defined in claim 1 wherein the step of providing acomponent comprises providing a sound module.
 9. The method of affixinga component as defined in claim 1 wherein the step of providing a filmcomprises providing a nylon film having an exterior metalized skin. 10.The method of firmly affixing a component as defined in claim 1 whereinthe step of placing the component onto the film comprises providing arobotic arm and manipulating the robotic arm to pick up the componentfrom a remote location and move the component to a predeterminedposition upon the one surface of the film.
 11. A method of manufacturingan inflatable object having a component affixed to the interior thereof,the method comprising the steps of: providing a component having asurface having at least a portion thereof coated with a heat activatablematerial to be affixed into the interior of an inflatable object,providing a first film comprised having one surface thereof comprised ofa plastic material that is adapted to be processed to form an inflatableobject, heat and pressure sealing the heat activatable material coatedsurface of the 20 component to the plastic surface of the first film,providing a second film having one surface thereof comprised of aplastic material, and peripherally heat sealing the first film to thesecond film to form a sealed envelope there between with the componentlocated within that sealed envelope.
 12. The method of manufacturing aninflatable object as defined in claim 11 wherein the steps of providinga first and second film comprise providing nylon films having interiorpolyethylene surfaces.
 13. A method of manufacturing an inflatableobject as defined in claim 11 further including the step of continuouslymoving the film and intermittently stopping the film to carry out thestep of heat and pressure sealing the heat activatable coated surface ofthe component to the plastic surface of the first film.
 14. A method ofmanufacturing an inflatable object as defined in claim 11 wherein thestep of providing a component comprises providing a sound module.
 15. Amethod of manufacturing an inflatable object as defined in claim 14wherein the sound module is comprised of a foam material having the heatactivatable material coating.
 16. A system for affixing a componentwithin an inflatable object, said system comprising: a system for movinga film having a plastic surface; means to stop the movement of the filmat predetermined intervals, a placement mechanism adapted to position acomponent having a heat activatable material coating onto the film at aselected location upon the film with the heat activatable materialcoated surface of the component facing the plastic surface of the film,a heater adapted to be normally located displaced from the film, theheater adapted to be moved to a location in close proximity to the filmso as to heat the film to affix the component to the film.
 17. Thesystem as defined in claim 16 wherein the heater is moved by a pistonfrom a lower position to be raised to an upper position beneath the filmin close proximity thereto.
 18. The system as defined in claim 16wherein a protective material is located intermediate the heater and thefilm during the heating process.
 19. The system of claim 18 wherein theprotective material is polytetrafluroethylene.
 20. 0The system of claim16 wherein the placement mechanism is a robotic arm.
 21. An inflatableobject comprised of a film having a plastic interior surface adapted tocontain an inflating gas and a component having a surface coated with aheat activatable material heat sealed to the plastic interior surface ofthe inflatable object.
 22. The inflatable object as defined in claim 21wherein the plastic interior surface of the inflatable object ispolyethylene.
 23. The inflatable object as defined in claim 22 whereinthe heat activatable material coating on the component is polyethylene.24. The inflatable object as defined in claim 21 wherein the heatactivatable material coating on the component is a heat activatableadhesive.
 25. The inflatable object as defined in claim 21 wherein thecomponent is a device capable of producing a sound or light.